Refractory cast block and method of producting the same



Jan. 24, 1939. G. s. FULCHER 2,145,113

REFRCTORY CAST BLOCK AND METHOD OF PRODUCING THE SAME Filed Dec?. 2l, 1956 Cw a Patented Jan. 24, 1939 PATENT OFFICE I REFRACTORY CAST BLOCK METHOD` O F PRODUCING THE SAIVIE Gordon S. Fulcher, Louisville, Ky., assignor to Corhart Refractorles Company, Louisville,

Appueatien December 21, 193s, `serial No. 117,019

3 Claims.

In my prior Patent No. 1,879,676 I have described a method of casting refractory materials in which previously solidified lumbs or particles 1 inserted in the mold during the assemblage thereof and being supported and located during the casting by their ends.

Referring to the accompanying drawing in which corresponding parts are designated by similar marks of reference,

Figure 1 is a vertical section through a mold having my invention incorporated therein.

Figure 2 is a horizontal section thereof.

Figure 3 is a section through a blo'ck produced by casting in the mold assembled as in the foregoing gures.

Referring to Figures 1 and 2, the mold I0 is g5 built up of slabs I0-a of sand bonded with linseed oil. During the assemblage of such a mold blocks Il in the form oi' slats are inserted therein, the slats extending into apertures in the side wall of the mold and being held in place thereby the block' to be cast. For this purpose the length of the slats should be greater than the width of the finished block. If desired. longitudinal slats II--a may be laid on the cross slats Il. These u slats are composed of sintered grains preferably 1 of the same composition and physical character as the cast block, but lf-desired such grains may have some small percentage of a bonding material, such as bond clay or linseed oil, added ,D thereto prior to the operation by which they are sintered. Good results by my invention have been obtained when the sintered slats have formed about 3% of the total weight of the blocks.

The mold parts being thus assembled, as shown in Figures 1 and 2, the mold is filled with the premelted refractory material (for instance, with the nowwell known material containing about 80% alumina and 20% silica) and the casting is slowly cooled. In this solidiflcation, solidiflcation takes place` not only from the sides but from around the slats, which improves the uniformity of temperature throughout the block and aids in obtaining a better crystal structure in the central portions thereof. Due to the high temperature at which the molten material is poured, on cooling it will b e found to adhere firmly to the slats.

After the cast block has cooled and the mold slabs i 0 removed, the ends of the slats l I will project from the sides thereof, as shown in Figure 3. Such projections may be readily removed.

Having thus described my invention, what I claim is:

1. A cast refractory block having a slat therein 'extending from side to side of the block and remote from the top and bottom surfaces thereof, the slats beingofsintered grains of the same material as the cast material and of the same physical characteristics as the cast material.

2. The hereinbefore described method of producing cast refractory blocks which comprises supporting refractory slats from their ends, casting the molten material around the slats intermediate of their ends, the slats being of sintered grains of the same material as the cast material and of the same physical characteristics as such material. l

3. The hereinbefore described method of producing cast refractory blocks which comprises supporting refractory slats from their ends, casting the molten material around the slats' intermediate of their ends, and removing the ends of the slats projecting beyond the cast material, the slats ybeing of sintered grains of the same material as the cast material and of the same physical characteristics as such material.

GORDON S. FULCI-DER. 

